Ceramic composite materials, articles, and methods

Patent metadata

Field	Value
Publication number	US-12428350-B2
Application number	US-202117185909-A
Country	US
Kind code	B2
Filing date	Feb 25, 2021
Priority date	Feb 19, 2018
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

Methods of forming composite materials, composite materials, and articles. The composite materials may include electromagnetic shielding materials. The methods may include providing a mixture of ultra-high temperature ceramic particles and a liquid preceramic precursor, curing the mixture to form a solid mixture, forming particles of the solid mixture, and pressing the particles into a mold.

First claim

The invention claimed is:

1. A composite material comprising:
a plurality of particles of a solid mixture, the solid mixture comprising ultra-high temperature ceramic particles and a polymer-derived ceramic;
wherein the ultra-high temperature ceramic particles are at least partially coated with the polymer-derived ceramic; and
wherein the plurality of particles is a plurality of discrete particles.

2. The composite material of claim 1 , wherein each discrete particle of the plurality of particles of the solid mixture comprises—
(a) a core region comprising an amount of the ultra-high temperature ceramic particles, and
(b) a surface region comprising an amount of polymer-derived ceramic;
wherein for each of the particles of the solid mixture—
(i) the amount of the ultra-high temperature ceramic particles of the core region includes at least 75%, by weight, of the ultra-high temperature ceramic particles that are present in each particle of the solid mixture, and
(ii) the amount of the polymer-derived ceramic of the surface region includes at least 75%, by weight, of the polymer-derived ceramic that is present in each particle of the solid mixture.

3. The composite material of claim 1 , wherein the ultra-high temperature ceramic particles have a melting temperature of at least 2,000° C.

4. The composite material of claim 1 , wherein the ultra-high temperature ceramic particles have at least one of the following properties: [1] an elastic modulus of at least 500 GPa, [2] a hardness of at least 20 GPa, [3] an electrical conductivity of at least 10 7 S/m, or [4] a thermal conductivity of about 60 to about 120 W/m*K.

5. The composite material of claim 1 , wherein the ultra-high temperature ceramic particles are selected from the group consisting of a boride, a carbide, and a nitride.

6. The composite material of claim 1 , wherein the ultra-high temperature ceramic particles comprise HfB 2 , ZrB 2 , TiB 2 , NbB 2 , TaB 2 , or a combination thereof.

7. The composite material of claim 1 , wherein the ultra-high temperature ceramic particles comprise TaC, HfC, ZrC, NbC, TiC, or a combination thereof.

8. The composite material of claim 1 , wherein the ultra-high temperature ceramic particles comprise TaN, HAN, TIN, ZrN, NbN, or a combination thereof.

9. An article comprising:
one or more surfaces, and
the composite material of claim 1 ;
wherein the composite material is arranged on the one or more surfaces of the article.

10. The article of claim 9 , wherein the composite material is an electromagnetic shielding material.

11. The article of claim 9 , wherein the article is at least part an aircraft or a submarine.

12. The article of claim 11 , wherein the at least part of the aircraft comprises a nosecone.

Assignees

• Univ Florida State Res Found Inc

Inventors

• Xu Cheryl

Classifications

• C04B35/515

  based on non-oxide ceramics · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• C04B35/6261

  Milling · CPC title

• C04B2235/61

  Mechanical properties, e.g. fracture toughness, hardness, Young's modulus or strength · CPC title

• C04B2235/602

  Making the green bodies or pre-forms by moulding · CPC title